Tufting machines for and the method of producing terry-like fabrics



Se t. 17, 1968 c. w. WATKINS 3,401,557

TUFTING MACHINES FOR AND THE METHOD OF PRODUCING TERBYLIKE FABRICS Filed Nov. 15, 1965 4 Sheets-Sheet 1 Fig.l

INVENTOR.

Charles W Watkins WITNESS BY fiwh/JVM A T TORNEY P 7, 1968 c. w. WATKlNS 3,401,657

TUFTING MACHINES FOR AND THE METHOD OF PRODUCING TERRY-LIKE FABRICS Filed Nov. 15, 1965 4 Sheets-Sheet 2 Fig.2

INVENTOR.

Char/as W (Wins WITNESS ATTQRNEY,

Sept, 1, 1968 c. w. WATKINS 3,401,657

TUFTING MACHINES FOR AND THE METHOD OF PRODUCING TERRY-LIKE FABRICS Filed Nov. 15, 1965 4 Sheets-Sheet 5 INVENTOR.

Charles W Wafkins WITNESS Z (wfJ 67 0M ATTORNEY Sept. 17, 1968 c. w. WATKINS 3,

TUFTING MACHINES FOR AND THE METHOD OF PRODUCING TERRY-LIKE FABRICS 4 Sheets-Sheet 4 Filed Nov. 15, 1965 INVENTOR. Charles W Watkins flwarc/ 03 M A TTORNEY WITNESS United States Patent 3,401,657 TUlFTING MACHINES FOR AND THE METHOD OF PRODUCING TERRY-LIKE FABRICS Charles W. Watkins, Hixson, Tenn., assignor to The Singer Company, New York, N.Y., a corporation of New Jersey Filed Nov. 15, 1965, Ser. No. 507,940 Claims. (Cl. 112-79) ABSTRACT OF THE DESCLOSURE This disclosure relates to textile machinery and in particular to tufting machines which through a novel method of operation is capable of producing novel pile fabrics such as terrycloth and the like. Basically, the novel machine disclosed herein includes means for projecting a first loop of yarn through a backing fabric, means for holding said first loop while the backing fabric is advanced, means for projecting a second loop of said yarn through said first loop of said yarn and means for holding said second loop of yarn in loose pile-like disposition and for collapsing said first loop of yarn around said second loop of yarn whereby said second projected loop is held in loose pile-like disposition by said first projected loop for forming a pile-like surface on at least One side of said backing fabric.

The present invention relates to a tufting machine for producing a terry-like fabric and has for an object to provide a tufting machine for making a terry-like fabric having loops from a single thread on both faces of a backing fabric.

Another object of this invention is to provide a tufting machine for producing a terry-like fabric, which machine is simple but at the same time is eflicient and will economically produce a quality fabric. It is a further object of this invention to provide a tufting machine which produces a terry-like fabric in which the yarn forming the pile loops cannot readily be pulled out.

The machine in accordance with this invention comprises a needle adapted to be moved endwise through a backing fabric, together with a pair of oppositely acting loopers on the opposite side of the backing fabric from the needle, which loopers are actuated at one half of the speed of the needle whereby the loopers will cooperate with the needle alternately upon successive stitches, one of said loopers being adapted to seize the loop of yarn presented by the needle and to hold it and present the same to the needle upon the succeeding stroke whereas the other looper is adapted to seize and to hold the loop presented by the needle upon such succeeding stroke. To form a loop of yarn on the needle face of the fabric there is provided a stitch supporting finger that is shifted laterally upon each stitch forming cycle so that a limb of the yarn is laid over the finger.

Having in mind the above and other objects that will be evident from an understanding of this disclosure, the invention comprises the devices, combinations and arrangements of parts as illustrated in the presently preferred embodiment of the invention which is hereinafter set forth in such detail as to enable those skilled in the art readily to understand the function, operation, construction and advantages of it when read in conjunction with the accompanying drawings in Which:

FIG. 1 is a vertical sectional view transversely of a machine embodying the present invention.

FIG. 2 is a fragmentary sectional view taken substantially on the line 22 of FIG. 1.

FIGS. 3 through 11 are detail sectional views of the loop forming instrumentalities of the machine of FIG. 1

3,401,657 Patented Sept. 17, 1968 "ice and illustrating the successive steps in the loop forming operation.

With reference to the drawings and particularly to FIGS. 1 and 2 thereof, the present invention is herein illustrated as embodied in a tufting machine having a frame 1 consisting of a pair of opposed side plates 2 and 3 disposed vertically in spaced parallel relation and cross pieces 4 and 5 extending between the same. The frame 1 is supported by a stand 6 that includes the vertical legs 7 connected at the top thereof by end pieces 8 and cross pieces 9, the side plates 2 and 3 being secured to the vertical web of the end pieces 8 as by welding.

A main shaft 10 is journaled in bearings 11 carried by the side plates 2 and 3 and is driven by a chain 12 that is entrained about a sprocket 13 on the end of the main shaft 10 outwardly of the side plate 3 and about a sprocket 14 on the output shaft 15 of a speed reducing unit 16 that is mounted on the stand 6 at the corner on the input side of the machine. The unit 16 is adapted to be driven by a belt 17 that is entrained about a pulley 18 on the input shaft 19 thereof.

Mounted on the cross piece 5 is a work-supporting needle plate 20 having fingers 21 that are spaced apart laterally of the machine on a uniform selected gauge and that extend from the plate 20 toward the rear or output side of the machine. A backing fabric F is adapted to be advanced across the needle plate 20 in the direction of the arrow A, FIG. 1, by a backing fabric feed means which includes a pair of driven let-off rolls 22 and a pair of feed rolls 23. The let-off rolls 22 are journaled in the side plates 2 and 3 at the bottom and at the input side of the machine on axes parallel to the axis of the main shaft 10 and are connected together for unitary rotation in opposite directions by intermeshing gears 24 (FIG. 2) secured thereon outwardly of the side plate 2 and are adapted to be driven from the main shaft 10 through a speed reducing unit 25 that is mounted on the top of the side plate 3. The unit 25 has a sprocket 26 on its output shaft 27 which sprocket is connected by a chain 28 to a sprocket 29 on the shaft of the upper one of the pair of rolls 22 at the end opposite from the end upon which the respective gear 24 is mounted, that is, the end outwardly of the side plate 3. The input shaft 30 of the unit 25 has a sprocket 31 that is connected by a chain 32 with a sprocket 33 on the main shaft 10. The feed rolls 23 are journaled in brackets 34 on the rear edges of the side plates 2 and 3 and are also arranged with the axes thereof parallel to the axis of the main shaft 10. The feed rolls 23 are driven from the rolls 22 by a chain 35 (FIG. 2) that is entrained about a sprocket 36 on the lower one of the rolls 22 at the same end as and outwardly of the gears 24, which chain 35 is also entrained about a sprocket (not shown) on the closer one of the feed rolls 23. The feed rolls 23 are driven at a slightly faster rate than the let-off rolls 22 in order to maintain the fabric under tension. Also, as shown in FIG. 1, the lowermost points of the rolls 22 and 23, which are the delivery point of the rolls 22 and the take up point of the rolls 23, are disposed substantially in the plane of the needle plate 20 so that the fabric F will be advanced flatly across the needle plate 20.

The needle mechanism of the machine comprises a plurality of push rods 37 that are mounted for endwise reciprocation in the cross piece 4 and at the lower ends thereof carry a needle bar 38 in which are mounted a plurality of needles 39 arranged upon a gauge corresponding to the gauge of the needle plate fingers 21 and staggered with respect thereto, whereby, upon reciprocation of the push rods 37, the needles 39 will penetrate the backing fabric F on the needle plate 20 and will pass downwardly between the fingers 21. Reciprocation is imparted to the push rods 37 by connecting rods 40 pivotally connected at their lower ends to the top of the push rods 37 by pins 41 and having straps 42 at their upper ends that encircle eccentrics 43 on the main shaft 10.

A measured amount of yarn Y is adapted to be fed to each needle upon each cycle of the machine by a yarn feed mechanism that comprises a pair of yarn feed rolls 44 journaled on axes parallel to the axis of the main shaft 10 in brackets 45 on the top edges of the side plates 2 and 3. The rolls 44 are interconnected for unitary rotation by gears 46 (FIG. 2) mounted on the ends thereof outwardly of the side plate 2 and are driven from the main shaft 10 through a speed reducing unit 47 mounted on the top edge of the side plate 2 behind the adjacent one of the brackets 45. The input shaft 48 of the unit 47 is provided with a sprocket 49 that is connected by a chain 50 to a sprocket 51 on the main shaft 10 while the output shaft thereof is connected by a chain 52 to a sprocket 53 on the shaft of the closer one of the rolls 44.

From the delivery side of the yarn feed rolls 44, the yarns Y pass to a yarn jerker 54 and through guides including a guide 55 on the cross piece 4 of the frame 1 and a guide 56 on the needle bar 38 to the needles 39. The yarn jerker 54 comprises a bar 57 which has a thread aperture 58 for each of the yarns Y, which bar 57 is mounted by means of brackets 59 on a shaft 60 that is journaled for oscillation in the side plates 2 and 3 in beari gs 61 and to which oscillation is imparted by a link 62 (FIG. 2) that is pivotally and adjustably connected at its upper end to a crank 63 secured to the shaft 60 on the end thereof outwardly of the side plate 2. At its lower end, the link 62 is connected by a strap 64 to an eccentric 65 on a rotary looper shaft 66 that is journaled between the side plates 2 and 3 in bearings 67 and is arranged beneath the needle plate 20 at the input side of the machine on a axis parallel to the axis of the main shaft 10. The function of the yarn jerker 54 is to expand the length of the yarn Y between the yarn feed rolls 44 and the guide 55 and thus, since the rolls 44 limit the amount of yarn present in the system by feeding only a predetermined amount thereto upon each cycle, the yarn jerker will pull yarn back from the needle when it is operated.

Rotation is imparted to shaft 66 by the main shaft 10 at a speed that is one-half the speed of the main shaft. The connection between the shafts 66 and 10 comprises a chain 68 that is entrained about a sprocket 69 on the end of the main shaft 10 outwardly of the side plate 3 and about a sprocket 70 on the shaft 66 that is twice the size of the sprocket 69 in order to get the 2:1 ratio.

Beneath the needle plate 20 there is provided a looper mechanism 71 which is herein referred to as the second looper mechanism since, of the two looper mechanisms, it is the second acting in each pile forming cycle. The looper mechanism 71 comprises a looper bar 72 carried by a plurality of rods 73 that are arranged substantially parallel to the needle plate 20 and are loosely mounted for endwise sliding in the cross piece 5 of the frame 1. The looper bar carrier a plurality of loopers 74 facing the direction of feed of the fabric F, that is, in the direction of the arrow A, and corresponding in number to the number of needles 39. The loopers 74 are arranged on the same gauge as the needles 39 but are slightly offset relative thereto whereby the loopers 74 will each cooperate in loop-seizing relation with a respective one of the needles 39. The loopers 74 are adapted to be actuated by eccentrics 75 on the looper shaft 66, which eccentrics are encircled by straps 76 that are pivotally connected by pivot pins 77 to the ends of the rods 73. Accordingly, upon rotation of the shaft 66, there is imparted to the loopers 74 endwise reciprocation including an advance on loop seizing stroke during which each of the loopers passes the respective one of the needles 39 in loop seizing relation and thus enters a loop of the yarn Y presented by the needle 39, and a return or loop shedding stroke.

Also disposed beneath the needle plate 20 is another .4 looper mechanism 78 which is herein referred to as the first looper mechanism since it acts before the looper mechanism 71 in each cycle. The looper mechanism 78 comprises a looper bar 79 carrying a plurality of loopers 80 which are opposed to the loopers 74 and, like the loopers 74, correspond in number to the number of needles 39 and are arranged on the same gauge as the needles 39 but are slightly offset relative thereto whereby the loopers 80 will each cooperate in loop-seizing relation with a respective arc of the needles 39. The looper bar 79 is mounted by brackets 81 on a looper shaft 82 journaled for oscillation in brackets 83 on the side plates 2 and 3 of the frame 1. Oscillation is imparted to the looper shaft 82 by the looper shaft 66 through an eccentric 84 on the shaft 66 that is encircled by the strap 85 at one end of a pitman 86 which at its other end, is pivotally and adjustably connected by a pivot pin 87 to a slotted crank 88 that is secured to the looper shaft 82.

Opposed to the needle plate 20 and space sufficiently above the same to permit the backing fabric F to pass freely between them is an upper stitch-supporting mechanism 89 that comprises a mounting plate 90 having a plurality of stitch-supporting fingers 91 lying substantially fiat on the fabric F and extending in the direction of feed of the fabric P, which fingers correspond to the needle plate fingers 21, that is, in the same manner as with the fingers 21, the fingers 91 correspond in number to the number of needles 39 that are spaced apart on the same gauge but are offset relatively to the needles 39 and are located so that the needles 39 will penetrate between the same. The plate 90 is mounted for sliding movement laterally of the machine to move the fingers 91 from one side to the other of the respective needles and for this purpose the plate 90 is carried by a rod 92 that is mounted for endwise sliding in the side plates 2 and 3 and has a cam follower 93 secured on the outer end thereof. To hold the rod 92 against turning and thus to shift the plate 90 and stitch supporting fingers 91 laterally, the follower 93 tracks a two-step cam groove 95 in the periphery of a barrel cam 96 that is mounted on a countershaft 97 journaled for rotation in a bearing 98 on the side plate 3 and a bearing 99 (partially shown in FIG. 2) that is carried by a bracket 100 secured to the side plate 3. Rotation is imparted to the countershaft 97 from the looper shaft 66 by a chain 101 entrained about a sprocket 102 in the shaft 97 and about a similar sprocket on the shaft 66.

With reference to FIGS. 3-11 there is illustrated the successive steps in the pile forming operation of a single set of pile forming instrumentalities, that is, one of the needles 39 and its cooperating loopers 74 and 90 and stitch supporting finger 91, the initial positions of the pile forming elements at the beginning of the cycle are illustrated in FIG. 3. As the needle 39 descends from the position of FIG. 3 in its fabric penetrating stroke, which may be termed the initial advance stroke of the needle in each cycle, it passes downwardly between an adjacent pair of the stitch-supporting fingers 91, through the backing fabric F at the point S1 and between an adjacent pair of the needle plate fingers 21, thus projecting a loop of the yarn Y through the backing fabric F. After the needle 39 has reached the bottom of its initial advance stroke and has begun its return stroke, the looper 80 advances to seize the loop presented by the needle 39, as illustrated in FIG. 4, and holds the same as the needle 39 continues its return stroke thereby providing the loop L1 on the bottom face of the backing fabric (FIG. 5). The looper 80, which is operated at one-half of the speed of the needle 39, continues to hold the loop L1 until the needle 39 again penetrates the fabric F at the point S2 on its next stroke, which is herein termed the alternate advance stroke of the needle in each cycle, at which time it presents the loop L1 to the needle which passes in loop seizing relation to the looper 80, FIG. 6. While the needle 39 was out of the fabric F, the fabric was advanced by the feed rolls 23 so that the points of penetration of the fabric by the needle 39 upon its initial and alternate advance strokes in the cycle that is, the points S1 and S2, are spaced in the direction that the fabric F, has moved and there is a length of the yarn Y, which is the back-stitch B, extending between the points S1 and S2 on the upper face of the work.

After the needle 39 has entered the loop L1 on the looper 80, the looper 80, which is then in its return stroke, releases the loop L1 (FIG. 7) and remains inactive or out of cooperation with the needle during the remainder of the cycle. At the same time, the looper 74, which also operates at one half the speed of the needle 39 and was out of cooperation with the needle during the initial advance stroke of the needle, is now advancing and passes the needle to seize the loop of yarn thereon after the needle has completed its advance or downward movement and has begun to rise to throw the loop L2 .(FIG. 8). The looper 74 then holds the loop of yarn that was presented by the needle on the alternate stroke while the needle completes its return movement to maintain the second loop L2 of yarn on the underside of the fabric F (FIG. 9). While the needle 39 is out of the fabric F, the fabric is again advanced and, at the same time, the plate 90, which is also operated at one-half the speed of the needle 39, is shifted laterally so that when the needle 39 descends on the initial advance stroke of the next cycle, it will pass on the opposite side of the finger 91 (FIG. 10) so that the limb of the yarn Y that extends between the point of penetration of the backing fabric F by the needle on the alternate stroke of the needle in the one cycle (i.e. the point S2) and the point of penetration or the initial stroke of the needle in the next cycle (i.e. the point S1) is laid over the finger to form a loop L3 on the upper face of the backing fabric. Thereafter, the looper 80 advances to seize and to hold the loop presented by the needle 39 and to present the same to the needle upon its alternate advance stroke in this cycle, thus repeating the pile forming cycle. As the fabric F is advanced, the loop L3 is moved off the finger 91. In FIG. 11 the fabric is illustrated at the end of the second pile forming cycle.

As will be seen, the loop L2 penetrates the loop L1 on the under face' of the fabric F and as thus interlocked, the yarn Y will resist being pulled out. As illustrated in FIG. 12, if the yarn Y were pulled as indicated by the arrow P, for example by snagging one of the loops L3, in order for the loop L1 to collapse in response to such pull, it must pull to one side the loop L2 that passes through it. Since the loop L1 engages the loop L2 at the base thereof, this interaction effectively resists pulling the yarn Y from the fabric F. The yarn jerker 57 functions to insure that the loop L1 is drawn tightly about the loop L2 by operating at the time that the needle 39 is descending on the alternate advance stroke of each cycle, that is, while the needle is moving downwardly and after it has seized the loop L1 from the looper 80, as shown in FIG. 7.

Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to a preferred embodiment of my invention which is for purposes of illustration only and not to be construed "as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.

Having thus described the nature of the invention, what I claim herein is:

1. In a tufting machine for producing a terry-like fabric, means for supporting a backing fabric and for 'advancing the same across said supporting means, and a plurality of sets of pile forming elements each of which includes a needle, means mounting said needle for endwise reciprocation on one side of the backing fabric and adapted to penetrate the backing fabric and to project a loop of yarn therethrough, and a first and a second looper, means said loopers on the opposite side of the backing fabric from said needle, actuating means for actuating said loopers to cooperate alternately with said needle in p seizing relation upon successive advance strokes thereof, said first looper facing in a direction opposite to the direction of feed of the backing fabric and being adapted to be actuated by said actuating means to seize and to hold the loop of yarn presented by the needle upon the initial advance stroke of each cycle and to present such initial loop to the needle upon the alternate advance stroke of each cycle whereby said needle will project such alternate loop of yarn through the initial loop of yarn, said second looper facing in the direction of feed of the backing fabric and being adapted to be actuated by said actuating means to seize such alternate loop of yarn presented by the needle and to hold the same during the return stroke of the needle.

2. In a tufting machine in accordance with claim 1 wherein said first and second loopers are operated by said actuating means at one-half the speed of said needles.

3. In a tufting machine in accordance with claim 1 wherein there is provided means for forming a loop of yarn on the face of the fabric adjacent to said needle comprising a stitch supporting finger, means mounting said stitch supporting finger adjacent to the path of said needle, and means for moving said finger laterally of the direction of feed of the fabric to the opposite sides of the needle whereby a loop of yarn will be laid over said finger.

4. A method of forming a pile fabric comprising, projecting a needle carrying a yarn through a backing fabric to form a first loop on one side of said backing fabric, engaging said first formed loop to hold said first formed loop on said one side of said backing fabric while the needle is withdrawn from the backing fabric, advan ing the backing fabric relative to the needle, projecting the yarn carrying needle through the backing fabric and through the first formed loop to thereby form a second loop on said one side of said fabric, releasing said first formed loop whereby said first formed loop collapses and surrounds said second formed loop, engaging said second formed loop to hold said second formed loop on said one side of the backing fabric, withdrawing said needle from the backing fabric and thereafter releasing said second formed loop such that said second formed loop projects loosely from said one side of the backing fabric and is engaged by said first formed loop.

5. A method of forming a pile fabric as recited in claim 4 comprising, again advancing the backing fabric relative to the needle, looping the yarn over a finger member to form a loop on the opposite side of the backing fabric from said one side of the backing fabric and projecting the needle again through the backing fabric and repeating the steps of forming said first and second formed loops on said one side of the backing fabric such that during advance of the backing fabric relative to the needle loosely projecting loops will be formed on both sides of said backing fabric.

References Cited UNITED STATES PATENTS 1,929,323 10/1933 Maier 112-197 XR 2,705,465 4/1955 Lacey 112-79 3,230,917 I/ 1966 Wignall et al 112-79 XR 3,309,900 3/1967 Wunsch et a1 112-79 XR 3,318,271 5/1967 DeRoberts et al. l12l99 XR FOREIGN PATENTS 57,347 3/1940 Denmark.

5,158 3/1896 Great Britain. 12,811 4/ 1898 Great Britain.

JORDAN FRANKLIN, Primary Examiner.

I. BOLER, Assistant Examiner. 

